Waterway connection

ABSTRACT

A coupler for a faucet is disclosed which couples a first waterway component and a second waterway component, the coupler being an overmold component.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to a connection between a firstwaterway component and a second waterway component and, moreparticularly, to an overmold coupler which secures the first waterwaycomponent to the second waterway component in a faucet assembly.

Faucets are generally controlled by either a single handle whichutilizes a mixing valve to proportion the flow of hot and cold water toa delivery spout, or dual-handles which utilize two individual valves tocontrol the flow of hot and cold water. The valve bodies which house therespective valves are each typically connected to an upstream waterwaythrough a conventional mechanical connection, such as mating threads.Further, each valve body is typically connected to a downstream waterwayby brazing the valve bodies to the downstream waterway. In otherexamples the valve bodies and the downstream waterway are cast as asingle component. Brazing requires additional time, assembly, andinspection. One of the problems with a brazing connection is thatundesirable materials, such as harmful metals may be communicated fromthe brazing material into the water passing through the connection.Additionally, brazing requires a etching operation to be performedsubsequent to the brazing operation.

In a exemplary embodiment of the present invention, a faucet forconnection to a water supply having a hot water supply and a cold watersupply is provided. The faucet comprising: a hot water inlet memberhaving a hot water fluid inlet adapted to be coupled to the hot watersupply, a hot water fluid outlet, and an internal waterway connectingthe hot water fluid inlet to the hot water fluid outlet; a cold waterinlet member having a cold water fluid inlet adapted to be coupled tothe cold water supply, a cold water fluid outlet and an internalwaterway connecting the cold water fluid inlet to the cold water fluidoutlet; a waterway component having a first fluid inlet, a second fluidinlet, a fluid outlet and an internal waterway connecting the firstfluid inlet, the second fluid inlet, and the fluid outlet; at least onecoupler configured to maintain the position of the hot water inletmember relative to the waterway component and to maintain the positionof the cold water inlet member relative to the waterway component, theat least one coupler being an overmold of at least a first portion ofthe hot water inlet member, a first portion of the cold water inletmember, and a first portion of the waterway component, the at least onecoupler coupling the hot water inlet member and the waterway componentsuch that the internal waterway of the hot water inlet member is influid communication with the internal waterway of the waterway componentand coupling the cold water inlet member and the waterway component suchthat the internal waterway of the cold water inlet member is in fluidcommunication with the internal waterway of the waterway component. Inan example, the at least one coupler includes a first overmold couplerwhich couples the hot water inlet member to the waterway component and asecond overmold coupler which couples the cold water inlet member to thewaterway component. In another example, the at least one couplerincludes a first overmold coupler which couples the hot water inletmember to the waterway component and the cold water inlet member to thewaterway component. In a variation the faucet further comprises a hotwater upstream waterway coupled to the hot water inlet member, the hotwater upstream waterway being positioned downstream from the hot watersupply and upstream to the hot water inlet member, wherein the firstovermold coupler further couples the hot water inlet member to the hotwater upstream waterway. In another variation, the faucet furthercomprises a cold water upstream waterway coupled to the cold water inletmember, the cold water upstream waterway being positioned downstreamfrom the cold water supply and upstream to the cold water inlet member,wherein the first overmold coupler further couples the cold water inletmember to the cold water upstream waterway. In a further example, thefaucet further comprises a first user input device configured to controla flow rate of hot water exiting the fluid outlet of the hot water inletmember, the first user input device being positioned above the at leastone coupler, and a second user input device configured to control a flowrate of cold water exiting the fluid outlet of the cold water inletmember, the second user input device being positioned above the at leastone coupler.

In another exemplary embodiment of the present invention, a faucet isprovided. The faucet comprising: a first waterway component of thefaucet having an internal waterway; a second waterway component of thefaucet having an internal waterway, the second component beingpositioned such that the internal waterway of the second waterwaycomponent is in fluid communication with the internal waterway of thefirst waterway component; a valve positioned within the first waterwaycomponent to control the flow rate of fluid through the first waterwaycomponent; a user input device coupled to the valve; and a couplerconfigured to maintain the position of the second waterway componentrelative to the first waterway component, the coupler being an overmoldof at least a first portion of the first waterway component and a firstportion of the second waterway component, wherein the coupler is spacedapart from the fluid being communicated by the internal waterways of thefirst waterway component and the second waterway component and whereinthe user input device is external relative to the coupler. In anexample, the coupler is made of a glass reinforced polypropylene. Inanother example, a seal is positioned between the first waterwaycomponent and the second waterway component. In a further example, thefirst waterway component and the second waterway component are housed inan escutcheon and the first user input device extends above theescutcheon.

In an exemplary method of the present invention, a method of assemblinga faucet is provided. The method comprising the steps of: providing afirst waterway component of the faucet having an internal waterway and asecond waterway component of the faucet having an internal waterway;positioning the first waterway component and the second waterwaycomponent in a mold such that a fluid outlet of the internal waterway ofthe first waterway component is generally positioned proximate to afluid inlet of the second waterway component; and molding a coupler overat least a portion of the first waterway component and at least aportion of the second waterway component, wherein the internal waterwayof the first waterway component and the internal waterway of the secondwaterway component are in fluid communication and the coupler is spacedapart from the internal waterway of the first waterway component and thesecond waterway component. In an example, the method further comprisesthe step of positioning a valve within the first waterway component, thevalve being configured to control the flow rate of fluid through theinternal waterway of the first waterway component, the valve beingpositioned within the first waterway component prior to the step ofmolding a coupler. In one variation, the method further comprising thesteps of: placing an escutcheon over the coupler; and coupling a firstuser input device to the valve, the first user input device beinglocated above the escutcheon.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1 is a is a diagrammatic view of a dual valve faucet having twovalve bodies each housing a valve, the valve bodies each being connectedto an adjacent waterway with one or more couplers;

FIG. 2 is a is a diagrammatic view of a single valve faucet having avalve body housing a valve, the valve body being connected to anadjacent waterway with one or more couplers;

FIG. 3 is an exemplary dual valve faucet assembly including a lowerassembly, an escutcheon, user handles coupled to respective valves ofthe lower assembly, and a spout in fluid communication with a waterwayof the lower assembly;

FIG. 4 is a bottom view of the lower assembly of FIG. 3;

FIG. 5 is a sectional view of the lower assembly taken along lines 5-5of FIG. 4;

FIG. 6 is an exploded perspective view of the lower assembly of FIG. 3;

FIG. 7 is a lower perspective view of a portion of the lower assemblywith a valve assembly exploded;

FIG. 8 is a lower perspective view of the lower assembly; and

FIG. 9 is an exploded view of a hot water valve body, a cold water valvebody, and a waterway component.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to the precise forms disclosed.Rather, the embodiments selected for description have been chosen toenable one skilled in the art to practice the invention. Although thedisclosure is described in connection with water, it should beunderstood that additional types of fluids may be used.

Referring to FIG. 1, an illustrative embodiment of a faucet assembly 100is shown. Faucet assembly 100 includes a hot water valve body 102 and acold water valve body 104. Each of hot water valve body 102 and coldwater valve body 104 are connected to an upstream waterway component106, 108 which is in turn connected to a hot water supply 110 and a coldwater supply 112, respectively An interior waterway in each of hot watervalve body 102 and cold water valve body 104 is in fluid communicationwith hot water supply 110 and cold water supply 112, respectively,through a respective internal waterway in upstream waterway components106, 108.

The internal waterway of each of hot water valve body 102 and cold watervalve body 104, is in fluid communication with an internal waterway in awaterway component 114. As such, water from hot supply 110 and waterfrom cold water supply 112 pass through hot water valve body 102 andcold water valve body 104, respectively, and into waterway component 114where they are mixed and provided to an internal waterway in adownstream waterway component 116. Downstream waterway component 116,such as a spout, is in fluid communication with a fluid outlet 118, suchas an aerator.

Hot water valve body 102 houses a valve 120 which is moveable between afirst position wherein water from hot water supply 110 is in fluidcommunication with waterway component 114 and a second position whereinwater from hot water supply 110 is not in fluid communication withwaterway component 114. In one embodiment, valve 120 is a rotatablevalve. The position of valve 120 is adjusted though a hot water userinput 124, such as a handle 125. Handle 125 generally extends aboveescutcheon 107 of faucet 100.

Similarly, cold water valve body 104 houses a valve 122 which ismoveable between a first position wherein water from cold water supply112 is in fluid communication with waterway component 114 and a secondposition wherein water from cold water supply 112 is not in fluidcommunication with waterway component 114. In one embodiment, valve 122is a rotatable valve. The position of valve 122 is adjusted though acold water user input 126, such as a handle 127. Handle 127 generallyextends above escutcheon 107 of faucet 100.

Suitable rotatable valves include the valves disclosed in U.S. Pat. Nos.3,645,493; 4,453,567; 4,577,835; and 4,700,928, the disclosures of whichare expressly incorporated by reference herein.

In one embodiment, hot water valve body 102 and cold water valve body104 are connected to upstream hot water waterway component 106 andupstream cold water waterway component 108, respectively, through aconventional connection. Exemplary conventional connections include amechanical connection, such as mating threaded portions with or withoutone or more seals. Hot water valve body 102 and cold water valve body104 are each connected to waterway component 114 through an overmoldcoupler 130, 132, respectively.

In one embodiment, overmold couplers 130, 132 are formed by the steps ofpositioning each of hot water valve body 102, cold water valve body 104,and waterway component 114 relative to each other such that therespective waterways of each are in fluid communication. This grouping(hot water valve body 102, cold water valve body 104, and waterwaycomponent 114) is positioned within a mold (not shown) which is designedto hold the grouping in place. In another embodiment the grouping iscreated by the placement of hot water valve body 102, cold water valvebody 104, and waterway component 114 in the mold. The mold is closed.Injection moldable material is introduced in the regions indicated byovermold couplers 130 and 132 in FIG. 1. The injection moldable materialcools and overmold couplers 130 and 132 are formed. In one embodiment,the injection moldable material is a thermoplastic material. Oneexemplary material is a glass reinforced polypropylene. Other exemplarymaterials include injection moldable materials having a sufficientstrength to maintain the position of the respective waterway componentswhen in use with pressurized fluid.

Each connection coupled by a respective overmold coupler 130, 132permits the transport of fluid there through. In one embodiment, anoutlet of the internal waterway of hot water valve body 102 ispositioned relative to the internal waterway of waterway component 114so that fluid may flow from hot water valve body 102 into waterwaycomponent 114. In one embodiment, the positioning of hot water valvebody 102 and waterway component 114 prevents the injection moldablematerial of overmold coupler 130 from contacting the fluid waterwaycreated by hot water valve body 102 and waterway component 114. As such,overmold coupler 130 is spaced apart for the fluid transported in fluidwaterway created by hot water valve body 102 and waterway component 114.

Similarly, in one embodiment, an outlet of the internal waterway of coldwater valve body 104 is positioned relative to the internal waterway ofwaterway component 114 so that fluid may flow from cold water valve body104 into waterway component 114. In one embodiment, the positioning ofcold water valve body 104 and waterway component 114 prevents theinjection moldable material of overmold coupler 132 from contacting thefluid waterway created by cold water valve body 104 and waterwaycomponent 114. As such, overmold coupler 132 is spaced apart for thefluid transported in fluid waterway created by cold water valve body 104and waterway component 114.

In one embodiment, a single overmold coupler 134 is used in place ofovermold couplers 130 and 132. Overmold coupler 134, like overmoldcouplers 130 and 132, is made from injection moldable material. Unlikeovermold couplers 130 and 132, overmold coupler 134 spans at least twoconnections, illustratively the connection between hot water valve body102 and waterway component 114 and the connection between cold watervalve body 104 and waterway component 114. As such, overmold coupler 134couples three components of the waterway assembly of faucet 100together. In addition, by utilizing a contiguous coupler 134 additionalstrength is provided to the waterway assembly of faucet 100. Thecomponents coupled together by overmold coupler 134 are positioned sothat the injection moldable material of overmold coupler 134 isprevented from contacting the fluid waterway created by the componentscoupled together. As such, overmold coupler 134 is spaced apart from thefluid transported in the fluid waterway created by the componentscoupled together by overmold coupler 134.

In the illustrated embodiment, hot water valve body 102, valve 120, coldwater valve body 104, valve 122, waterway component 114, and therespective overmold coupler (either 130 and 132, or 134) are at leastpartially housed within an escutcheon 107. In another embodiment, anexternal surface of coupler 134 is visible to the operator. Similarly,downstream waterway component 116 is housed within a spout 109.

As used herein waterway assembly is used to indicate the respectiveovermold coupler or components and the components coupled togetherthereby. In an example, a first waterway assembly includes hot watervalve body 102, waterway component 114, and overmold coupler 130. Inanother example, a second waterway assembly includes cold water valvebody 104, waterway component 114, and overmold coupler 132. In a furtherexample, a third waterway assembly includes hot water valve body 102,cold water valve body 104, waterway component 114, and overmold coupler134.

In one embodiment, an overmold coupler, similar to overmold coupler 130couples hot water valve body 102 and upstream hot water waterwaycomponent 106. In another embodiment, an overmold coupler, similar toovermold coupler 132 couples cold water valve body 104 and upstream coldwater waterway component 108. In still a further embodiment, overmoldcoupler 134 couples together the following pairs of components: (1) hotwater valve body 102 and upstream hot water waterway component 106, (2)hot water valve body 102 and waterway component 114, (3) cold watervalve body 104 and upstream cold water waterway component 108, and (4)cold water valve body 104 and waterway component 114. In one example,upstream hot water waterway component 106 and upstream cold waterwaterway component 108 each include a flexible tubing portion which isat least partially located outside of overmold coupler 134. As such,during installation of faucet 100, the waterway assembly includingovermold coupler 134 may be positioned relative to the sink (not shown)and the only fluid connections required for installation would bebetween the flexible tubing of upstream hot water waterway component 106and hot water supply 110, such as the hot water isolation valve, andbetween the flexible tubing of the upstream cold water waterwaycomponent 108 and the cold water supply 112, such as the cold waterisolation valve.

In one embodiment, an overmold coupler 131, similar to overmold coupler130 couples waterway component 114 and downstream waterway component116. In another embodiment, overmold coupler 134 couples together thefollowing pairs of components: (1) hot water valve body 102 and waterwaycomponent 114, (2) cold water valve body 104 and waterway component 114,and (3) waterway component 114 and downstream waterway component 116. Inone example, wherein downstream waterway component 116 correspondsgenerally to a spout, overmold coupler 134 extends generally down to theaerator associated with the spout. In another embodiment, downstreamwaterway component 116 and waterway 114 are a single component, such asan injection molded component.

In another embodiment, overmold coupler 134 couples together thefollowing pairs of components: (1) hot water valve body 102 and upstreamhot water waterway component 106, (2) hot water valve body 102 andwaterway component 114, (3) cold water valve body 104 and upstream coldwater waterway component 108, (4) cold water valve body 104 and waterwaycomponent 114; and (5) waterway component 114 and downstream waterwaycomponent 116. As such, each connection of faucet 100, except for theconnections between faucet 100 and the respective hot water supply 110and cold water supply 112 are maintained by overmold coupler 134.

Although the above discussion has illustrated a single upstream hotwater waterway component 106, a single upstream cold water waterwaycomponent 108, and a single downstream water 116, it should beunderstood that the use of one or more overmold couplers may be extendedto multiple upstream hot water waterways 106, multiple upstream coldwater waterways 108, and/or multiple downstream waterways 116. Further,waterway component 114 may be formed of multiple waterways which arecoupled together through the use of one or more overmold couplers.

Referring to FIG. 2, another exemplary faucet 200 is illustrated. Faucet200 is similar to faucet 100 expect that a single valve body 202 isconnected to both upstream hot water waterway component 106 and upstreamcold water waterway component 108 and downstream waterway component 116.Valve body 202 houses a valve 204 which controls the flow rate of boththe hot water and the cold water that enters valve body 202. The hotwater and the cold water are at least partially mixed within valve body202. In one embodiment, valve 204 is a ball valve. Exemplary valves aredisclosed in U.S. Pat. No. 6,920,899 and U.S. Provisional ApplicationSer. No. 60/662,106 Attorney Docket No. DFC-P0034, filed Mar. 14, 2005),the disclosures both of which are expressly incorporated by referenceherein.

Valve 204 is actuatable by a hot/cold water user input device 208. Inone example, user input device 208 includes a handle 210. In oneembodiment, valve 204 and valve body 202 are generally covered by anescutcheon 206. In another embodiment, an external surface of coupler234 is visible to the operator. User input device 208 generally extendsbeyond escutcheon 206. Illustratively, user input device 208 is shownbelow escutcheon 206. In one embodiment, user input device 208 ispositioned above escutcheon 206.

Each of the following connections may be coupled by a respectiveovermold coupler: (1) upstream hot water waterway component 106 andvalve body 202 are illustratively coupled by overmold coupler 130; (2)upstream cold water waterway component 108 and valve body 202 areillustratively coupled by overmold coupler 132; and (3) valve body 202and downstream waterway component 116 are coupled together by overmoldcoupler 230. Similar to faucet 100, one or more of the overmold couplersmay be combined in a single overmold coupler. Illustratively overmoldcouplers 130, 132, and 230 may be replaced with a single overmoldcoupler 234. In one embodiment, the respective overmold couplers providestructural support for faucet 200 in addition to maintaining theconnections between the various components.

Referring to FIGS. 3-9, a faucet 300 is shown. Referring to FIG. 3,faucet 300 is a dual handle faucet having a first handle 302 configuredto be actuatable by a user to control the flow rate of hot water and asecond handle 304 configured be actuatable by a user to control the flowrate of cold water. Each of handles 302 and 304 is coupled to arespective valve stem 306, 308 of a hot water valve 310 and a cold watervalve 312.

Valves 310 and 312 are shown as rotatable cartridge valves. Exemplarycartridge valves are disclosed in U.S. Pat. Nos. 3,645,493; 4,453,567;4,577,835; and 4,700,928, the disclosures of which are expresslyincorporated by reference herein. Referring to FIG. 6 each valve 310,312 includes a respective valve cartridge 314A, 314B, seal assembly316A, 316B, and stop 318A, 318B. Stops 318A, 318B are configured tointeract with cartridges 314A, 314B to limit the rotation of therespective valve stem 306, 308. In one embodiment, stop 318A ispositioned so that valve stem 306 (and hence handle 302) is moveablebetween the position shown in FIG. 3 and approximately 90° in direction307 and stop 318B is positioned so that valve stem 308 (and hence handle304) is moveable between the position shown in FIG. 3 and approximately90° in direction 309.

Each of seal assemblies 316A, 316B include a sleeve 320, a spring 322,and a seat 324. As explained below, seal assemblies 316A, 316B interactwith respective valve cartridges 314A, 314B to regulate the flow offluid through respective valves 310, 312. The following discussion isgenerally related to the assembly and operation of valve 310 relative toa valve body 340A. However, it is also applicable to the assembly andoperation of valve 312 relative to valve body 340B.

Referring to FIG. 7, valve cartridge 314A is shown. Valve cartridge 314Aincludes an internal waterway 330A (see FIG. 5) which has a fluid inlet332A formed as an opening 334A in a plate 336A and a fluid outlet 338A.Referring to FIG. 5, valve 310 is housed in a valve body 340A. Valvebody 340A includes a lower portion 342A having a threaded external wall344A configured to threadably mate with an upstream waterway component(not shown). Valve body 340A further includes an upper portion 346Ahaving a threaded external wall 348A. Valve 310 is positioned within aninternal cavity 352A of valve body 340A and held in place with a coupler350A, illustratively a bonnet nut.

Valve body 340A includes an internal waterway 354A having a firstportion 356A, a second portion 358A, and a third portion 360A. In theabsence of blockage by valve 310 water enters internal waterway 354Afrom an upstream waterway (not shown) at fluid inlet 359A, travelsgenerally vertically through first portion 356A and second portion 358A,then generally horizontally through third portion 360A, and out fluidoutlet 361A to a downstream waterway component, illustratively waterwaycomponent 370.

Seal assembly 316A is positioned generally within second portion 358A ofwaterway 354A and valve cartridge 314A is positioned in third portion360A of waterway 354A. Spring 322A biases seat 324A upward such thatseat 324A presses against plate 336A (see FIG. 7) to prevent water fromleaking between seat 324A and plate 336A. Once valve 310 is positionedin valve body 340A, bonnet nut 350A is threaded onto upper portion 346Aof valve body 340A to hold valve 310 in place. In operation, when valve310 is open, water passes generally vertically through first portion356A of waterway 354A, generally vertically through a waterway 362A ofseat 324A (which is positioned in second portion 358A of waterway 354A),generally vertically into fluid channel 338A of valve cartridge 314A(which is positioned in third portion 360A of waterway 354A), generallyhorizontally in fluid channel 338A of valve cartridge 314A and out fluidoutlet 361A. When valve 310 is closed, plate 336A is rotated (due to therotation of cartridge 314A) such that opening 334A is not aligned withfluid channel 362A in seat 324A. As such, water is prevented fromentering fluid channel 338A of valve cartridge 314A. Further, due to theforce of spring 322A water may not leak between seat 324A and plate336A.

Referring to FIG. 9, fluid outlet 361 (361B shown) is coupled to a fluidinlet 380 (380A is shown) of a waterway component 370. Fluid outlet is361 is positioned in portion 366A, 366B of valve bodies 340A, 340B whichare illustratively shown as being generally hex-shaped with a flatsurface 368 (368B shown) providing fluid outlet 361.

Waterway component 370 includes two generally tubular portions 371A,3711B each having an internal waterway 382A, 382B and each configured tomate with valve bodies 340A, 350B respectively. Portions 371A, 371B aregenerally shown to be arranged in a V-shaped arrangement. Thisarrangement is to provide clearance for a drain assembly (not shown) offaucet 300 as explained below. In other embodiments, portions 371A, 371Bmay be generally co-linear. further, waterway component 370 may becomprised of multiple waterway components which are coupled together byan overmold component 400.

Each portion 371A, 371B includes a flange 372A, 372B and a seal surface376A, 376B. A seal 378A, 378B is positioned over seal surface 376A, 376Band rests against surface 374 (374A shown) of flanges 372A, 372B. Seals378A, 378B also rest against a seal surface 369 (369B shown) of valvebodies 340A, 340B when valve bodies 340A, 340B are coupled to waterwaycomponent 370. Although the positioning of seal 374A, 374B may holdvalve bodies 340A, 340B and waterway component 370 together absent anexternal force and/or fluid flowing through the respective valve bodies340A, 340B and waterway component 370, additional coupling is required.

Waterway component 370 further includes an upright portion 386 having awaterway 384. Upright portion 386 includes a reduced portion 388 whichis configured to be coupled to a downstream waterway 440 (see FIG. 3)illustratively shown within a spout 442 (see FIG. 3). As such, assumingboth valves 310, 312 are open, hot water from valve body 340A entersfirst portion 371A of waterway component 370 and cold water from valvebody 340B enters second portion 371B of waterway component 370. The hotwater and cold water are combined in waterway component 370 and flowthrough upright portion 386 into downstream waterway 440 and out offluid outlet 444.

Referring back to FIG. 3, an overmold coupler 400 is shown. Overmoldcoupler 400 is made by molding a thermoplastic material around portionsof valve body 340A, valve body 340B, and waterway component 370.Exemplary thermoplastic materials include glass reinforcedpolypropylene. Overmold coupler 400 surrounds flanges 374A, 374B ofwaterway component 370 and portions 366A, 366B of valve bodies 340A,340B, respectively. As best shown in FIG. 5, the presence of overmoldmaterial behind flanges 374A, 374B assists in preventing waterwaycomponent 370 from moving relative to either of valve bodies 340A, 340Bwhich would have been possible in the absence of overmold coupler 400.Overmold component 400 assists in maintaining a fluid tight seal betweenvalve bodies 340A, 340B, and waterway component 370 by holding therespective components together.

Since overmold coupler 400 couples valve bodies 340A, 340B and waterwaycomponent 370 together without the need for brazing, valve bodies 340A,340B and waterway component 370 may be made from dissimilar materialsand non-metallic materials. In one embodiment, valve bodies 340A, 340Bare machined from brass stock and waterway component 370 is made from athermoplastic material through an injection molding operation. Inanother embodiment, valve bodies 340A, 340B are made from a brass sleevewherein the internal structure such as second portion 358A, 358B whichholds seal assembly 316A, 316B and seat surface 369 of fluid outlet361A, 361B are made from a thermoplastic material through an injectionmolding operation.

In addition to coupling valve bodies 340A, 340B, and waterway component370 together, overmold coupler 400 in the illustrated embodiment mayfunction as a mounting component as well. Referring to FIG. 8, a lowersurface 402 of overmold coupler 400 provides a flat surface for layingflush relative to a top surface of a sink (not shown). In oneembodiment, a gasket (not shown) is positioned between lower surface 402and the top surface of the sink. Further, in one embodiment, overmoldcoupler 400 may be configured to receive a coupler or cam fastenerconfigured to couple faucet 300 to the sink mounting deck (not shown) asshown in U.S. Pat. Application Ser. No. (unknown), filed concurrentlyherewith, Attorney Docket No. DFC-P0046, titled “Overhead Cam FaucetMounting System,” the disclosure of which is expressly incorporated byreference herein.

Referring to FIG. 4, overmold coupler 400 further includes mountingapertures 410A, 410B each having an associated seat surface 412A, 412B.Mounting apertures 410A, 410B each receive a coupler (not shown) whichis received in a mounting aperture (not shown) of spout 442 (see FIG.3). In one embodiment, the couplers are bolts whose heads press againstseat surfaces 412A, 412B to hold spout 442 relative to overmold coupler400. Further shown in FIG. 4, is an aperture 414 which is sized toreceive a lift rod of a pop-up drain assembly (not shown) which couplesa knob/handle 432 (see FIG. 3) to a drain plug (not shown) in the sink.

As seen in FIG. 8, the mold which creates overmold coupler 400 includescore out portions (a first one illustrated as 404) which provides ribs(a first one illustrated as 406) as well as reducing the amount ofmaterial required to make overmold coupler 400 which aids in maintainingthe shape of overmold coupling 400 as it cools. As shown, in FIG. 8, atop surface 408 of ribs 406 is offset inward relative to lower surface402 of overmold coupler 400. Ribs 406 provide additional structuralrigidity to overmold coupler 400.

In one embodiment, overmold coupler 400 is manufactured by placingwaterway component 370, valve body 340A, valve body 340B, and seals378A, 378B in a mold (not shown) as inserts. It is well known in theinjection molding art to mold a thermoplastic material around one ormore inserts positioned in the mold.

The components are either individually placed or placed as an assembly.In either case, the components are assembled such that seal 378A isgenerally contacting surface 369A of valve body 340A and surface 374A ofwaterway component 370 and such that seal 378B is generally contactingsurface 369B of valve body 340B and surface 374B of waterway component370. Once the mold is closed the thermoplastic material is injected intothe mold which is configured to form the overmold coupler shown in FIGS.3-8. As such, overmold coupler 400 is spaced apart for the fluidtransported in fluid waterway created by valve body 340A, valve body340B, and waterway component 370. It should be understood that althoughovermold coupler 400 is shown as a separate component in FIG. 6, it isnot a separate component that is assembled to the other components, butrather a molded component which is formed over various portions of valvebody 340A, valve body 340B, and waterway component 370 by a moldingoperation.

In one embodiment, referring to FIG. 5, the mold shuts off againstsurface 390A, 390B of lower portion 354A, 354B of valve bodies 340A,340B, against side surfaces 392A, 392B of bonnet nuts 352A, 352B, andagainst surface 394 of waterway component 370. As such, in oneembodiment, valves 310, 312 may be assembled into their respective valvebodies 340A, 340B with bonnet nuts 352A, 352B secured thereto prior toovermold coupler 400 being formed. In another embodiment, the mold mayshut off against a top surface 397A, 397B and a bottom surface 399A,399B of portions 366A, 366B of valve bodies 340A, 340B. The overalldiameter of portions 366A, 366B may be increased, as necessary, for topsurface 397A, 397B and bottom surface 399A, 399B to provide a sealingsurface for the mold.

In one embodiment, waterway component 370 is connected to waterwaycomponent 440 through conventional couplers. In another embodiment,similar to overmold components 134 and 234, overmold component 400 mayinclude additional connections such as between waterway connector 370and waterway component 440 and/or various upstream waterway components(not shown).

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

1. A faucet for connection to a water supply having a hot water supplyand a cold water supply, the faucet comprising: a hot water inlet memberhaving a hot water fluid inlet adapted to be coupled to the hot watersupply, a hot water fluid outlet, and an internal waterway connectingthe hot water fluid inlet to the hot water fluid outlet; a cold waterinlet member having a cold water fluid inlet adapted to be coupled tothe cold water supply, a cold water fluid outlet and an internalwaterway connecting the cold water fluid inlet to the cold water fluidoutlet; a waterway component having a first fluid inlet, a second fluidinlet, a fluid outlet and an internal waterway connecting the firstfluid inlet, the second fluid inlet, and the fluid outlet; at least onecoupler configured to maintain the position of the hot water inletmember relative to the waterway component and to maintain the positionof the cold water inlet member relative to the waterway component, theat least one coupler being an overmold of at least a first portion ofthe hot water inlet member, a first portion of the cold water inletmember, and a first portion of the waterway component, the at least onecoupler coupling the hot water inlet member and the waterway componentsuch that the internal waterway of the hot water inlet member is influid communication with the internal waterway of the waterway componentand coupling the cold water inlet member and the waterway component suchthat the internal waterway of the cold water inlet member is in fluidcommunication with the internal waterway of the waterway component. 2.The faucet of claim 1, wherein the at least one coupler includes a firstovermold coupler which couples the hot water inlet member to thewaterway component and a second overmold coupler which couples the coldwater inlet member to the waterway component.
 3. The faucet of claim 2,wherein the first overmold coupler and the second overmold coupler aremade from a glass reinforced polypropylene.
 4. The faucet of claim 1,wherein the at least one coupler includes a first overmold coupler whichcouples the hot water inlet member to the waterway component and thecold water inlet member to the waterway component.
 5. The faucet ofclaim 4, wherein the first overmold coupler is made from a glassreinforced polypropylene.
 6. The faucet of claim 4, further comprising ahot water upstream waterway coupled to the hot water inlet member, thehot water upstream waterway being positioned downstream from the hotwater supply and upstream to the hot water inlet member, wherein thefirst overmold coupler further couples the hot water inlet member to thehot water upstream waterway.
 7. The faucet of claim 4, furthercomprising a cold water upstream waterway coupled to the cold waterinlet member, the cold water upstream waterway being positioneddownstream from the cold water supply and upstream to the cold waterinlet member, wherein the first overmold coupler further couples thecold water inlet member to the cold water upstream waterway.
 8. Thefaucet of claim 4, further comprising an escutcheon covering the atleast one coupler and a downstream waterway coupled to the fluid outletof the waterway component, the downstream waterway extending above a topsurface of the escutcheon.
 9. The faucet of claim 8, wherein the firstovermold coupler further couples the waterway component and thedownstream waterway.
 10. The faucet of claim 9, wherein each of the hotwater inlet member and the cold water inlet member transport therespective hot water and cold water in a generally vertical directionfollowed by a generally horizontal direction, wherein the waterwaycomponent transports the respective hot water and cold water in agenerally horizontal direction followed by a generally verticaldirection.
 11. The faucet of claim 1, further comprising a first userinput device configured to control a flow rate of hot water exiting thefluid outlet of the hot water inlet member, the first user input devicebeing positioned above the at least one coupler, and a second user inputdevice configured to control a flow rate of cold water exiting the fluidoutlet of the cold water inlet member, the second user input devicebeing positioned above the at least one coupler.
 12. The faucet of claim11, wherein the first user input device is a first handle coupled to arotatable valve positioned within the hot water inlet member and thesecond user input device is a second handle coupled to a rotatable valvepositioned within the cold water inlet member.
 13. The faucet of claim4, further comprising a hot water upstream waterway coupled to the hotwater inlet member, the hot water upstream waterway being positioneddownstream from the hot water supply and upstream to the hot water inletmember and a cold water upstream waterway coupled to the cold waterinlet member, the cold water upstream waterway being positioneddownstream from the cold water supply and upstream to the cold waterinlet member, wherein the first overmold coupler further couples the hotwater inlet member to the hot water upstream waterway and the cold waterinlet member to the cold water upstream waterway.
 14. A faucet,comprising: a first waterway component of the faucet having an internalwaterway; a second waterway component of the faucet having an internalwaterway, the second component being positioned such that the internalwaterway of the second waterway component is in fluid communication withthe internal waterway of the first waterway component; a valvepositioned within the first waterway component to control the flow rateof fluid through the first waterway component; a user input devicecoupled to the valve; and a coupler configured to maintain the positionof the second waterway component relative to the first waterwaycomponent, the coupler being an overmold of at least a first portion ofthe first waterway component and a first portion of the second waterwaycomponent, wherein the coupler is spaced apart from the fluid beingcommunicated by the internal waterways of the first waterway componentand the second waterway component and wherein the user input device isexternal relative to the coupler.
 15. The fluid delivery system of claim14, wherein the coupler is made of a glass reinforced polypropylene. 16.The fluid delivery system of claim 14, wherein a seal is positionedbetween the first waterway component and the second waterway component.17. The fluid delivery system of claim 14, wherein the first waterwaycomponent and the second waterway component are housed in an escutcheonand the first user input device extends above the escutcheon.
 18. Amethod of assembling a faucet, the method comprising the steps of:providing a first waterway component of the faucet having an internalwaterway and a second waterway component of the faucet having aninternal waterway; positioning the first waterway component and thesecond waterway component in a mold such that a fluid outlet of theinternal waterway of the first waterway component is generallypositioned proximate to a fluid inlet of the second waterway component;and molding a coupler over at least a portion of the first waterwaycomponent and at least a portion of the second waterway component,wherein the internal waterway of the first waterway component and theinternal waterway of the second waterway component are in fluidcommunication and the coupler is spaced apart from the internal waterwayof the first waterway component and the second waterway component. 19.The method of claim 18, further comprising the step of positioning avalve within the first waterway component, the valve being configured tocontrol the flow rate of fluid through the internal waterway of thefirst waterway component, the valve being positioned within the firstwaterway component prior to the step of molding a coupler.
 20. Themethod of claim 19, further comprising the steps of: placing anescutcheon over the coupler; and coupling a first user input device tothe valve, the first user input device being located above theescutcheon.